Installation and method for conditioning a sheet of moulding material

ABSTRACT

An installation for winding sheets of molding materials exiting a machine wherein at least two coil devices are provided at space locations horizontally with respect to an exit of the machine, and wherein the sheet material is directed to the coils by way of a horizontally movable carriage including a main frame and a secondary frame, which is adjustable horizontally relative to the main frame, and which carriage is movable horizontally to direct the sheet material to a selected one of the at least two coils.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an installation and to a method forconditioning a sheet of moulding material on coils at the exit of amachine for producing a moulding material in sheet form.

2. Brief Description of the Related Art

Such a material, commonly called “SMC” (Sheet Moulding Compound) isproduced continuously on a machine which may be of type known fromFR-A-2 778 360 or of any other type. Such a machine functions withoutinterruption and a system must be provided for conditioning the sheet ofSMC produced, this system being compatible with the speed of advance ofthe sheet at the exit of the machine. When coils adapted to receiveabout 300 to 700 kg of material are used, it is possible to employ asystem incorporating rocker provided with two mandrels supporting thecoils, the material being alternately wound on each of these mandrels.

However, for at least certain applications, it is necessary to providethe use of large-capacity coils, such coils not being able to bemanipulated by a system incorporating rocker, due to their weight anddimensions.

SUMMARY OF THE INVENTION

It is a more particular object of the invention to overcome this problemby proposing a novel installation which is compatible with thecontinuous functioning of an SMC producing machine and with the use ofcoils of considerable mass and diameter.

In this spirit, the invention relates to an installation of theafore-mentioned type, which comprises:

at least two locations for positioning coils winding the sheet of SMC,such locations being in succession in a substantially horizontaldirection,

a carriage constituted by a main frame and a secondary frame, providedwith rollers guiding the sheet and mobile in translation, in theafore-mentioned direction, between a first position locatedsubstantially above a first location and a second position locatedsubstantially above the second location, and reciprocally, the main andsecondary carriages being adapted to slide with respect to each otherparallel to the afore-mentioned horizontal direction.

Thanks to the invention, the use of two successive locations makes itpossible to provide, for each location, adapted means for supporting anddriving the web of moulding material, while the carriage makes itpossible to take the sheet of moulding material up to each of the coilsrespectively installed in each of these locations. The bipartite natureof the carriage of the invention makes it possible to vary its lengthparallel to the horizontal direction of advance of the sheet. It is thuspossible to provide a compact configuration of this carriage, forexample when it is not used, and an extended position which allows it toguide the sheet of moulding material over a relatively considerablelength. The conditions of support of the sheet at the exit of themoulding material producing machine may thus be optimized.

According to advantageous aspects of the invention, the installationincorporates one or more of the following characteristics:

The carriage is equipped with a device for driving the sheet, thisdevice being mobile, concomitantly to the employment of sheet cuttingmeans, between a position of engagement with the sheet and a positiondisengaged with respect thereto. In particular, this device may beprovided to comprise a frame supporting a motorized roller and afollower roller, these rollers each being centered on an axissubstantially perpendicular to the direction of advance of the sheet andsurrounded by a drive belt, while this frame is articulated on thecarriage about an axis substantially perpendicular to this direction,between a first position where the belt is in contact with the sheet anda second position where the belt is remote from the sheet, and viceversa.

The carriage is equipped with a cutting device mounted on a framearticulated on the carriage about an axis substantially perpendicular tothe direction of advance of the sheet. The cutting device may thereforebe activated by its frame pivoting about its axis of articulation.

The carriage is equipped with a terminal guiding device extending, inconfiguration of use of the carriage, in the direction of a coil in thecourse of being filled, the guiding device being articulated on thecarriage about an axis substantially perpendicular to the direction ofadvance of the sheet. The articulated nature of this guiding devicemakes it possible to retract it when the carriage is not being used.

The main and secondary frames are equipped with rollers for supportingthe sheet in its movement of advance.

The carriage is adapted to be displaced towards a standby position whereit does not interfere with the path of the sheet. This aspect of theinvention makes it possible to use an SMC producing machine both toproduce coils of SMC of considerable weight, greater than 1000 kg, andcoils of SMC of the order of 300 to 700 kg, such as known previously.

Each coil is mounted in a principal chassis in which it is adapted torest, by the peripheral edges of its end plates, on blocking shoes,while the principal chassis is adapted to be placed on an auxiliarychassis equipped with rollers adapted to lift the afore-mentioned edgeswith respect to the shoes when the principal chassis is placed on theauxiliary chassis. The use of these two chassis makes it possible toprovide a blocking by default of a coil inside the principal chassisthanks to the use of the shoes, such blocking being eliminated when thecoil and the principal chassis are placed on the auxiliary chassis, theidly mounted rollers making it possible to support the end plates of thecoil with a possibility of rotation.

The auxiliary chassis is equipped with wheels allowing it to slide in adirection substantially perpendicular to the direction of advance of thesheet. This transverse access makes it possible to carry out theoperations of positioning and of evacuation of the coils in masked time.

The invention also relates to a method of conditioning which may becarried out with the installation described hereinbefore and, morespecifically, to a method which comprises the steps consisting in usingtwo types of coils of different diameter at the exit of the machine,depending on the quantity of matter to be wound, while

when coils of relatively smaller diameter are used,

they are supported by a rocker disposed opposite the exit zone of themachine, and

when coils of relatively larger diameter are used,

-   -   a coil adapted to be driven in rotation is installed in at least        one of two locations for positioning coils located downstream of        the rocker with respect to a direction of advance of the sheet,    -   a mobile carriage is disposed, substantially above the coil,        provided with guiding rollers on or against which the sheet was        previously arranged,    -   the sheet is driven from the carriage in order to displace the        front edge of this sheet up to contact with the mandrel of the        coil,    -   the coil is driven in rotation until the desired quantity of        material is wound,    -   the sheet is cut in the vicinity of the carriage, and    -   the carriage is displaced up to above the second location in        which a second coil was previously installed.

A BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more readily understood and other advantagesthereof will appear more clearly in the light of the followingdescription of a form of embodiment of an installation in accordancewith its principle and of its method of functioning, given solely by wayof example and made with reference to the accompanying drawings, inwhich:

FIG. 1 is a schematic representation of an installation according to theinvention in a first configuration of use.

FIG. 2 is a view similar to FIG. 1 while the installation is in a secondconfiguration of use.

FIG. 3 is a plan view of the installation in the configuration of FIG.1.

FIG. 4 is a longitudinal section on a larger scale of a part of thecarriage used in the installation of FIGS. 1 to 3.

FIG. 5 is a section similar to FIG. 4 while the installation is inanother configuration of use.

FIG. 6 is a schematic representation of the system for driving the coilsused in the installation.

FIG. 7 is an exploded view, on a larger scale, of the elements locatedin a location of the installation, and

FIG. 8 is a view similar to FIGS. 1 and 2 in another configuration ofuse of the installation.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The installation according to the invention is arranged at the exit of amachine 1 for producing composite moulding material of SMC type, in theform of a sheet 2 circulating along a path represented by arrows F₁ inthe Figures. The machine 1 is equipped with a “jumping jack” element 3for compensating the variations in length and speed of advance of thesheet 2.

As is more particularly visible in FIG. 8, the sheet 2 may be wound overthe mandrel 4 a or 4′a of coils 4 and 4′ supported by the arms of arocker 5 disposed opposite the exit zone of the machine 1. In theconfiguration shown in FIG. 8, the sheet 2 is in the course of beingwound on the coil 4, while coil 4′ may be either loaded on the rocker 5,or unloaded therefrom before being stored on a transport pallet 6disposed in the vicinity. This use of the machine 1 corresponds to theknown state of the art.

When the coils 14 and 14′ of large diameter d are to be used,particularly for winding the sheet 2 in quantities greater than 1000 kg,two locations 15 and 15′ are used, successively provided to the rear ofthe rocker 5 in a substantially horizontal direction X-X′ of advance ofthe sheet 2 after it has left the machine 1. These locations 15 and 15′are accessible in two directions Y₁-Y′₁, Y₂-Y′₂ substantiallyperpendicular to direction X-X′.

The direction X-X′ is substantially parallel to the path F₁ of the sheet2 in its upper part, after it has left the machine 1.

In this way, and as is visible in FIG. 3, it is possible to position anempty coil 14′ in the location 15′ by a translation in the direction ofthe arrow F₂ in FIG. 3, this arrow being parallel to direction Y₂-Y′₂.When coil 14 is filled, it is possible to remove it, as represented byarrow F₃ which is parallel to direction Y₁-Y′₁. In this way, anintervention F₂ or F₃ on one of the coils 14 or 14′ has no influence onthe coil 14′ or 14 located in an adjacent location 15′ or 15.

A carriage 20 rests on rails 21 above the rocker 5 and the locations 15and 15′. This carriage is equipped with a plurality of rollers 22 makingit possible to support the sheet 2 in its movement of advance F₁, theserollers being mounted idly on two frames, namely a main frame 20A and asecondary frame 20B each provided with wheels 23A, 23B respectively,allowing them to slide along the rails 21, as represented by arrow F₄.The wheels 23A rest on the rails 21 while wheels 23B, which are locatedat the right height for the frame 20B disposed at a level lower thanthat of frame 20B, rest on the lower flanges of the rails 21 which havea substantially C-shaped cross-section.

An electric motor 29 drives certain wheels 23A for the displacement ofthe carriage 20 on the rails 21. The motor 29 is controlled by themonitoring unit of the machine 1.

A jack 24 is mounted on the main frame 20A. The secondary frame 20B isfast with the rod 24 b of the jack 24, with the result that the distancee between the frames 20A and 20B may be adjusted by means of the jack24.

The total length L of the carriage 20 is provided to be sufficient forthe sheet 2 to be efficiently guided, forming a substantially horizontaland planar web on the rollers 22. In this way, the length of thecarriage 20 may be adjusted thanks to the jack 24, as a function of thecharacteristics of the sheet 2, these characteristics being able to varydue to its composite nature. The adjustment of the length of thecarriage 20 also makes it possible to adjust the tension of winding ofthe sheet 2.

On the contrary, when the carriage 20 is not used, as shown in FIG. 8,the jack 24 is retracted in order to reduce the total dimensions of thecarriage 20 parallel to direction X-X′.

20C denotes the edge of the carriage 20 which extends, perpendicularlyto direction X-X′, opposite the machine 1.

When the coil 14 is to be filled, the carriage 20 is positioned on therails 21 so that its edge 20C is disposed substantially above the coil14. In this way, that part 2 a of the sheet 2 stretched between thecarriage 20 and the coil 14 extends in a plane only slightly inclinedwith respect to the vertical. The part 2 a of the sheet 2 coming fromthe carriage 20 may therefore be easily wound on the mandrel 14 a of thecoil 14 suitably driven in rotation in the direction of arrow R.

A device 25 for guiding the part 2 a of the sheet 2 is constituted by aframe 251 articulated on the frame 20A about an axis Y₂₅ substantiallyperpendicular to the direction X-X′. This frame bears, at its endopposite axis Y₂₅, two rollers 252 and 253 defining therebetween a slot254 for passage of the sheet 2. The frame 251 also supports a plate 255which extends over the whole width of the carriage 20. The position ofthe frame 251 about axis Y₂₅ is controlled thanks to two jacksrepresented by their axis lines 256 articulated on the frame 20A and ofwhich the rod is fast with the frame 251.

The frame 251 remains in the position shown in FIGS. 4 and 5 except whenthe carriage 20 is not used, as in the configuration of FIG. 8, in whichcase the jacks 256 are contracted in order to return the rollers 252 and253 up to the immediate vicinity of the frame 20A in order to reduce thedimensions of the carriage 20.

A cut-out device 26 is articulated on the frame 20A about an axis Y₂₆substantially parallel to axis Y₂₅, i.e. perpendicular to the directionX-X′. The device 26 comprises a frame 261 supporting a rodless jack 262controlling a blade 263. Two jacks represented by their axis lines 266are articulated on the chassis 20A and make it possible to controlpivoting of the frame 261 about axis Y₂₆.

During filling of the coil 14, the device 26 is in the position of FIG.4 where it does not interfere with the sheet 2. When the coil 14 hasbeen filled, the jacks 266 are activated in order to bring the frame 261into the configuration of FIG. 5 where the blade 263 is in contact withthe sheet 2. The jack 262 then displaces the blade 263 along the plate255, thus cutting the sheet 2.

It is then possible to proceed with the final winding of the sheet 2 onthe coil 14.

When the sheet 2 has been cut, it no longer undergoes any effort oftension due to the movement of rotation of the coil 14. It shouldtherefore be avoided that the sheet 2 sets off again in the direction ofthe machine 1 under the effect of the elastic effort exerted by theelement 3. To that end, the carriage 20 is equipped with a device 27 fordriving and blocking the sheet 2 which comprises a frame 271 articulatedabout an axis Y₂₇ on the frame 20A and of which the displacement iscontrolled thanks to two jacks represented by their axis lines 276. Theframe 271 supports a first roller 272 which extends parallel to therollers 22 and to the axis Y₂₇ and which is motorized thanks to anelectric motor 274. The frame 271 also supports a second roller 273mounted idly and parallel to the roller 272. A belt 275 formed by metallinks is stretched around the rollers 272 and 273 and may be set intomotion by the controlled rotation of the roller 272.

22 a denotes the roller supported by the frame 20A and disposed as closeas possible to the edge 20C, i.e. the roller 22 which is the last on thepath of the sheet 2.

Concomitantly to the displacement of the frame 261, the frame 271 isdisplaced in the direction of the frame 20A by the jacks 276, so thatthe belt 275 is firmly applied against the sheet 2 in abutment on theroller 22 a. The distance e′ of rollers 272 and 273 is chosen so thatthe roller 22 a may be partially engaged between the rollers 272 and273, as represented in FIG. 5. In this configuration, the belt 275 actslike a brake to a possible movement of withdrawal of the sheet 2 in thedirection opposite to arrows F₁. To that end, the motor 274 may beblocked. This motor is equipped with a gear motor thus increasing thevalue of the load moment, this preventing the return of the sheet 2.

When the sheet 2 has been cut by the blade 263, the carriage 20 isdisplaced so that its edge 20C lies substantially above the coil 14′which was positioned in the location 15′ in parallel to the winding ofthe sheet 2 on the coil 14. From this configuration, the motor 274 isactivated so that the roller 272 is driven in the direction of arrow F₅in FIG. 5, which has the effect, taking into account the pressureexerted by the jack 276 and the firm abutment of the belt 275 on thesheet 2, of driving the sheet 2 in the direction of arrows F₁, so thatits free edge which was previously located at the level of the plate 255progresses in the direction of mandrel 14′a of the coil 14′ around whichthe sheet 2 then begins to be wound. The coil 14′ is then rotated andthe jacks 275 are activated in order to move the belt 275 away from thesheet 2.

One is then in the position of FIG. 2 where the filling of the coil 14′may take place, while the coil 14 may be evacuated in the direction ofarrow F₃ in FIG. 3.

During the filling of coil 14′, the coil 14 is evacuated and a freshcoil is placed in position. When the coil 14′ is full, one proceeds asindicated hereinabove for the coil 14 and the carriage 20 is returnedabove the location 15.

In this way, continuous functioning of the installation can beenvisaged.

In order to render the drawings clearer, devices 25 to 29 have beenomitted from FIGS. 1 to 3 and 8, except for rollers 252 and 253.

The drive system 28 of the coils 14 and 14′ is shown solely in FIG. 6 inorder to render the drawings clearer. It comprises an electric motorequipped with a gear motor 281 of which the driven shaft is coupled to aplate 282 provided with two fingers 283 intended to be introduced inopenings 141 provided between bars 142 at the centre of each end plate143 of the coils 14 or 14′. When the fingers 283 have been introduced inthe openings 141 and when the motor 281 is activated, the fingers comeinto contact with two bars 142 on which they may exert a torque forrotation of the coil 14 or 14′ in question.

The system 28 is mobile in directions Y₁-Y′₁, Y₂-Y′₂ and X-X′, so thatit may be alternately brought into engagement with one or the other ofthe coils 14 or 14′.

Each coil 14 or 14′ is supported by a chassis 16 or 16′ formed by angleswelded or assembled by bolting. The lower cross-ties 161 of the chassis16 are of U-section, with webs of large thickness giving them a gooddimensional stability, including when they are manipulated relativelysuddenly with lift trucks. Each chassis 16 or 16′ defines four shoes 162in arc of cylinder form disposed level with the end plates 143 of thecoils 14 and equivalent. By default, each coil 14 rests, by each endplate 143, on two shoes 162, so that, taking into account its weight andthe forces of friction between the edges 144 and the side plates 143 andthe shoes 162, the coil 14 is immobilized in rotation about its centralaxis Y₁₄. This corresponds to the position shown in FIG. 7 which is thatof the coil l 4 when it must be stored or transported.

When the coil 14 is to be rotated about its axis Y₁₄, in particular forconditioning the sheet 2 or for unwinding it with a view to use thereof,the chassis 16 is installed, as represented by arrows F₆, on anauxiliary chassis 17 constituted by cross-ties 171 extending insubstantially horizontal directions and from which supports 172 upwardlyproject, on which supports are idly mounted rollers 173 which are fourin number and which are arranged so that, when the chassis 16 is placedon the chassis 17, the edges 144 of the end plates 143 rest on therollers 173, being detached from the shoes 162. To that end, the heighth₁ of the centres of the rollers 173 with respect to the upper face ofthe cross-ties 171 is greater than the height h₂ of the lower part ofthe edge 144 of the end plate 143 with respect to the lower surface ofthe cross-ties 161.

Each auxiliary chassis 17 is equipped with wheels 174 allowing it toslide, perpendicularly to the direction F₁ of advance of the sheet 2, onrails 7 extending in the floor of the installation in directions Y₁-Y′₁,and Y₂-Y′₂, as represented in FIG. 3.

Functioning is as follows: when an empty coil 14′ is to be disposed inthe location 15′, the auxiliary chassis 17′ intended for this locationis taken into a position offset with respect to the zone of advance ofthe sheet 2, this position being shown in FIG. 3. In this position, acoil 14′ installed in a chassis 16′ is placed on the chassis 17′, whichmakes it possible to release the possibility of rotation of this coilabout its central axis while the coil 14′ remains captive of the chassis16′. The carriage 17′ is then translated in the direction of thelocation 15′, as represented by arrow F₂.

When a full coil is to be withdrawn from the installation, such as coil14, the carriage 17 being intended for the location 15, the chassis 16and the coil 14 are taken to the position represented in dashed anddotted lines in FIG. 3 and the simple fact of lifting the chassis 16with respect to the chassis 17 makes it possible to immobilize the coil14 in rotation inside the chassis 16 in question.

A system of indexing the position of the chassis 17 and 17′ along therails 7 may be provided by means of a finger 175 elastically loaded inthe direction of the floor and adapted to be engaged in holes 8 providedin the ground at the level of the position of the chassis 17 and 17′ ineach of the locations 15 and 15′ and in each of the positions ofloading/unloading of the principal chassis on the auxiliary chassis.

The invention has been shown with two coils 14 and 14′ disposed in twolocations 15 and 15′. However, it is also applicable with three or morethan three locations, the number of coils used being adapted accordinglywithout disturbing the functioning of the production line, particularlyof the machine 1.

The invention has been described during its implementation with a sheetof SMC. However, it is applicable with other sheet moulding materials,such as mats or fiber fabrics.

1. Installation for coiling a sheet of molding material on coils at anexit of a machine for producing molding material in sheet form, theinstallation including: at least two locations (15, 15′) for positioningat least two coils (14, 14′) for winding a sheet material (2), suchlocations being spaced in a substantially horizontal direction (X-X′)from the exit end of the machine, a carriage (20) including a main frame(20A) and a secondary frame (20B) provided with rollers (22) for guidingsaid sheet material and reciprocally movable in translation (F₄) betweena first position located substantially above a first of said at leasttwo locations and a second position located substantially above a secondof said at least two locations and said main (20A) and secondary (20B)frames being movable with respect to each other parallel to saidhorizontal direction (X-X′).
 2. Installation according to claim 1,wherein said carriage (20) includes a driving means (27) for drivingsaid sheet material (2) toward said at least two coils, said saidcarriage carrying cutting means (26) for cutting said sheet material,said cutting means being moveable between a position of engagement withsaid sheet material and a position disengaged with respect to said sheetmaterial.
 3. Installation according to claim 2, wherein said drivingmeans includes a frame (271) supporting a motorized roller (272) and afollower roller (273), said rollers each centered on an axissubstantially perpendicular to a direction (F₁) of advance of said sheetmaterial (2) and surrounded by a drive belt (275), while said frame(271) is articulated on said carriage 20 about an axis (Y₂₇)substantially perpendicular to said direction of advance, between afirst position where said belt is in contact with said sheet materialand a second position where said belt is remote from said sheetmaterial.
 4. Installation according to claim 1 wherein said carriage(20) carries a cutting device (26) mounted on a frame (261) articulatedon carriage about an axis (Y₂₆) substantially perpendicular to said adirection of advance (F₁) of said sheet material (2).
 5. Installationaccording to claim 1 wherein said carriage (20) includes a terminalguiding device (25) selectively movable relative to said carriage andfrom said carriage in a direction toward a coil (14, 14′) said guidingdevice being articulated on said carriage so as to pivot about an axis(Y₂₅) which extends substantially perpendicular to a direction ofadvance (F₁) of said sheet material.
 6. Installation according to claim1 wherein said main (20A) and secondary (20B) frames carry rollers (22)for supporting said sheet material (2) in a direction of advance (F₁).7. Installation according to claim 1 wherein said carriage (20) ismoveable towards a standby position where it does not interfere with apath of a direction of advance (F₁) of said sheet material (2). 8.Installation according to claim 1 wherein each coil (14; 14′) is mountedon a principal chassis (16, 16′) on which it is adapted to rest, by wayof peripheral edges (144) of end plates (143) on blocking shoes (162),and said principal chassis are adapted to be placed on auxiliary chassis(17, 17′) provided with rollers (173) which lift said edges with respectto said shoes when said principal chassis are placed on said auxiliarychassis.
 9. Installation according to claim 8, wherein each auxiliarychassis (17, 17′) includes wheels (174) allowing it to slide in adirection (Y1 -Y′₁, Y2 -Y′₂) substantially perpendicular to a directionof advance (F₁) of said sheet material.
 10. A method of coiling a sheetof molding material on coils at an exit of a machine for producingmolding material in sheet form using at least two types of coils (4, 4′,14, 14′) of different diameters at the exit of the machine dependingupon a quantity of sheet material to be wound, the method including thesteps of: A. when coils (4, 4′) of a relatively small diameter are to beused, coiling the sheet material on coils (4, 4′) supported on a rocker(5) adjacent the exit of the machine; B. when coils (14, 14′) ofrelatively larger diameter are to be used, positioning at least twolarger coils (14, 14′) down stream and at spaced locations (15,15′) withrespect to one another, and spaced from the rocker in a horizontaldirection (X-X′) of advance of the sheet material; C. providing acarriage (20) having a main frame (20A) and a secondary frame (20B)which is horizontally movable relative to the main frame andhorizontally adjusting the carriage to a first position spaced from thecoils (4, 4′)so as to be substantially above one of the at least twocoils (14, 14′); D. driving the sheet material from the carriage inorder to displace the sheet material from the carriage to place thesheet material into contact with a mandrel (14 a) of the one of the atleast two coils (14, 14′); E. after a desired quantity of the sheetmaterial is wound on the mandrel (14 a), cutting the sheet material andthereafter moving the carriage to substantially above a second of the atleast two coils (14, 14′); and thereafter F. driving the sheet materialfrom the carriage and coiling the material on a manderal (14′a) until adesired quantity of sheet material is coiled thereon and thereaftercutting the sheet material.